Rug and method of manufacturing the same



Aug. 9, 1932. c wAlTE 1,871,249

RUG AND METHOD OF MANUFACTURING THE SAME Filed March 1, 1930 inu e/r 0K TA/m 0. Pg?

Patented Aug. 9, 1932 umrao s'r Es PATENT oFFicE PHILIP o'. WAITE, or OSHKOSH, wrsoonsm, AssIGNon 'ro WAITE (mar na: COMPANY.

' or OSHKOSH, WISCONSIN, A CORPORATION 01* wrsconsm RUG Aim METHOD or MANUFACTURING THE sAME Application filed March 1; 19ao.r seiia1 No. 432,455.

This invention relates to rugs and method of manufacturing the same.

The present invention is directed toa method of making, dyeing and finishing rugs tufted with rayon silk, and has for its object to produce a pile surfaced rug havinga furlike texture adapted to reflect the light in such a way as to present a beautiful sheen,

and in which the fine rayon fibres or filaments are so intermeshed and intermingled as to conceal the presence of the separated tufts composing the pile of the rug.

In the manufacture of rugs in accordance with the method of the present invention, I employ a ground or backing which is preferably of canvas or similar fabric, and stitch the backing material with rows of stitches, which are in each instance looped and cut on the front side of the rug to form closely spaced rows of separated tufts, which stand away from the backing and constitute the pile of the present invention.

A suitable method and mechanism for forming the tufts constitutes the subject matter of co-pending application, Serial No. 428,872, filed February 17, 1930, so'that it is not here deemed necessary to describe said method or mechanismv in detail.

In order to secure'the sheen effect, which is the characteristic feature of the present:

invention, I employ in the tufting and stitching, bundled strands of rayon filaments known in the trade as thrown rayon strands, in which the individual filaments are of exceeding fineness and possess a luster which peculiarly adapts them to the requirements of the present invention.

The bundled strands of thrown rayon are only slightly twisted to maintain the strands in bundled formation, so that when the tufts have been formed, the individual rayon vfilaments will easily spread out or separate from one another to present their tips in diverging relation, so that the surface of the rug will present the appearance of a continuously extending pile surface and conceal the individual tufting and conceal the strandemployment of undyed materials permits the i-ted of the individual filaments, which are of gos- It is necessary to bring the individual tufts into such close proximity to one another that the spreading of the free ends of the filamentswill unite or intermesh the constituent filaments'of proximate tufts into a continuous intermeshing surface in which the individual rayon filaments are free to catch and reflect light and produce the sheen-like effect above referred After the rug hasbeen stitchedto form tufts of the character mentioned, it still presents the effect ofiindividual tufts, and in order to more completely separate the fila-v ments and give to the rug the intended tex-. ture, it is necessary to either subject the rug to a dyeing or a washing treatment.

The invention in its most perfected form contemplates the use of white -or undyed thrown rayon strands which are preferably stitched through a white backing, and the rug to be dyed to the desired color after the tufting operation has been performed.

The extreme fineness and quality of the thrown rayon filaments permits the rug, after tufting,to be dyed by immersion for a. few minutes in a suitable dye, during which limperiod it has been found that the tips samer fineness, will more qulckly absorb the dye and thus acquire a deeper shade of color than the underlying portions of the tufts, and it has also been found that the immersion in the dye liquid serves to more perfectly spread or separate the filaments andlntermesh them together to afford a continuous surface texture, so that, after removal from the dye liquid, and after drying, the rug W111 present an extremely soft, smooth and even fur-like texture, which effect is enhanced by reason of the fact that the tips are more deeply colored, so that when the surface of the rug is stroked down the underlying lighter colored portions of the rayon will be more "or less exposedto give an effect very closely resembling that of-natural fur.

If it is desired to further increase the luster'of the rug, after dyeing, the same can be subjected to a bath of soluble oil, which icompletes the treatment and affords arug of extremely soft and fine texture and lustrous appearance.

Although it is preferred to tuft the rug with undyed strands of thrown rayon, a similar result may be attained by the use of dyed strands, which after tufting are subjected the tufting operation and before the individual loops are cut to form tufts;

Fig. 3 illustrates the formation of the tufts after the loops have been severed; and

Fig. 4 illustrates the final condition of the rug after dyeing or washing to distend the filaments and obliterate the tufting effect.

In the drawing, the original thrown rayon strand A is stitched through the backing fabric B to form loops C, which are next cut to present the free ends D of the thrown rayon strand, which are afterwards spread'or dis-- tended to present a substantially continuous pile surface E, as in Fig. 4:.

Of course, it will be understood that the continuity of the pile surface will depend in considerable measure upon the closeness with which the tufts are spaced, and it will not always be possible to completely eliminate the effects of the tufting, so that in some cases, a

* slight ribbing effect will be observable in the completed rug, due to the formation of rows of stitchin but in all cases the tufting or stitching e ectwvill be largely, if not entirely, concealed or obliterated, so that the completed rug will in a large measure present the appearance of natural fur.

Although I have referred to the product of the present invention as a rug, it will be understood that I do not limit such product strictly to use as a rug, but on the contrary intend to include in that designation any.

fabric having characteristic features of the present invention, whether used as a floor covering, or as an imitation fur intended for wearing apparel, or for any other purpose to which the present invention may be put.

It will also be understood that under the term thrown rayon I include a rayon strand of loosely bundled formation having filaments of gossamer-like fineness and having the capacity to separate or distend under the present treatment, but that I do not 1nclude strands of ordinary rayon of comparatively coarse texture and which are customarily tightly twisted together and do not have the capacity for spreading or distension which s requisite in the manufacture of rugs havmg the characteristics of the present invention.

I claim:

1. The process of making rugs or the like, which consists in closely tufting a backing with loosely bundled strands of thrown rayon having filaments of gossamer-like fineness, and in thereafter subjecting the rug to a bath in a liquid dye to separate, distend and intermesh the free filament ends of the tufts to afford a substantially continuous and unbroken fur-like surface, and to dye the tips of the filaments to a deeper shade than the underlying portions of the tufts.

2. The process of making rugs or the like, which consists in closely tufting a backing with loosely bundled strands of thrown rayon having filaments of gossamer-like fineness, and in thereafter subjecting the rug to a bath in a liquid dye to separate, distend and intermesh the free filament ends of the tufts to afford a substantially continuous and unbroken fur-like surface, and to dye the tips of the filaments to a deeper shade than the underlying portions of the tufts, and in finally applying oil to the fur-like surface to increase the luster.

3. A rug or the like of the character described, including a backing having secured thereto closely spaced tufts, each tuft having its base portion in compacted relation and entered through the backing, and having its free tip ends distended to afford a substantially continuous fur-like surface, the tufts being formed of loosely bundled strands of thrown rayon composed of filaments of gassamer-like fineness, and the filaments of each tuft extending outwardly in diverging and progressively separated relation, and the marginal filaments of individual tufts contact ing and intermesh-ing with the filaments of contiguous tufts to conceal the tufting arrangement, and the rug being dyed to impart a deeper coloration to the surface tips of the filaments than to the underlying portions thereof.

In witness that I claim the foregoing I have hereunto subscribed my name this 12th day of February, 1930.

PHILIP C. WAITE. 

